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Brother HL 820 - 1020 - 1040 - 1050 Laser Printer Service Manual
Brother HL 820 - 1020 - 1040 - 1050 Laser Printer Service Manual
LASER PRINTER
SERVICE MANUAL
MODEL:HL-820/1020/1040/1050
Apr. 98
84U006BE0
PREFACE
This service manual contains basic information required for after-sales service of the laser printer
(here- in-after referred to as "this machine" or "the printer"). This information is vital to the service
technician to maintain the high printing quality and performance of the printers.
This service manual covers the HL-820, 1020, 1040 and 1050 laser printers. (Note that any figures
for the printer body are based on the HL-1040 printer.)
This manual consists of the following chapters:
CHAPTER I :
Information in this manual is subject to change due to improvement or re-design of the product. All
relevant information in such cases will be supplied in service information bulletins (Technical
Information).
A thorough understanding of this printer, based on information in this service manual and service
information bulletins, is required for maintaining its print quality performance and for improving the
practical ability to find the cause of problems.
CONTENTS
CHAPTER I
1. FEATURES .........................................................................................................................I-1
2. SPECIFICATIONS ..............................................................................................................I-3
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Printing.......................................................................................................................................I-3
Functions ...................................................................................................................................I-3
Electrical and Mechanical ..........................................................................................................I-4
Paper Specification ....................................................................................................................I-5
Print Delivery..............................................................................................................................I-5
Paper .........................................................................................................................................I-6
Effective Printing Area ...............................................................................................................I-7
1.4
1.5
2. MECHANICS....................................................................................................................II-26
2.1
2.2
2.3
2.4
2.5
Sensors...................................................................................................................................II-29
2.3.1 Cover Sensor.............................................................................................................II-29
2.3.2 Toner Empty Sensor..................................................................................................II-29
Drum Unit................................................................................................................................II-30
2.4.1 Photosensitive Drum .................................................................................................II-30
2.4.2 Primary Charger ........................................................................................................II-30
2.4.3 Developer Roller........................................................................................................II-30
2.4.4 Transfer Roller........................................................................................................... II-30
2.4.5 Cleaner Roller............................................................................................................ II-30
2.4.6 Erase Lamp ..............................................................................................................II-30
Print Process ..........................................................................................................................II-30
2.5.1 Charging ...................................................................................................................II-30
2.5.2 Exposure Stage .........................................................................................................II-31
2.5.3 Developing.................................................................................................................II-32
2.5.4 Transfer .....................................................................................................................II-32
2.5.5 Drum Cleaning Stage ................................................................................................II-33
2.5.6 Erasing Stage ............................................................................................................II-33
2.5.7 Fixing Stage...............................................................................................................II-33
4. PACKING........................................................................................................................III-18
ii
2. CONSUMABLE PARTS....................................................................................................IV-3
2.1
2.2
2.3
APPENDICES
1. Serial No. Descriptions ......................................................................................................A-1
2. Connection Diagram, HL-820/1020 ...................................................................................A-2
3. Connection Diagram, HL-1040 ..........................................................................................A-3
4. Connection Diagram, HL-1050 ..........................................................................................A-4
5. Main PCB Circuit Diagram, (HL-820/1020/1040), (1/2)......................................................A-5
6. Main PCB Circuit Diagram, (HL-820/1020/1040), (2/2)......................................................A-6
7. Main PCB Circuit Diagram, (HL-1050), (1/5)......................................................................A-7
8. Main PCB Circuit Diagram, (HL-1050), (2/5)......................................................................A-8
9. Main PCB Circuit Diagram, (HL-1050), (3/5)......................................................................A-9
10. Main PCB Circuit Diagram, (HL-1050), (4/5)....................................................................A-10
11. Main PCB Circuit Diagram, (HL-1050), (5/5)....................................................................A-11
12. Panel Sensor PCB Circuit Diagram .................................................................................A-12
13. Low-voltage Power Supply PCB Circuit Diagram, HL-820/1020/1040 (110 - 120V) ........A-13
14. Low-voltage Power Supply PCB Circuit Diagram, HL-820/1020/1040 (220 - 240V) ........A-14
15. Low-voltage Power Supply PCB Circuit Diagram, HL-1050 (110 - 120V) ........................A-15
16. Low-voltage Power Supply PCB Circuit Diagram, HL-1050 (220 - 240V) ........................A-16
17. High-voltage Power Supply PCB Circuit Diagram............................................................A-17
18. How to Know Drum Unit Life & Page Counter .................................................................A-18
19. Diameter / Circumference of Rollers ................................................................................A-20
iii
FEATURES
This printer has the following features:
High Resolution and Fast Printing Speed
<HL-820>
True 600 dots per inch (dpi) with microfine toner and 8 pages per minute (ppm) printing
speed (A4 or Letter paper).
<HL-1040/1020>
True 600 dots per inch (dpi) with microfine toner and 10 pages per minute (ppm) printing
speed (A4 or Letter paper).
<HL-1050>
True 600 dots per inch (dpi) and 1200 x 600 dpi for graphics with microfine toner and 10
pages per minute (ppm) printing speed (A4 or Letter paper).
Enhanced Printing Performance and User-Friendly Operation for Windows
The dedicated printer driver and TrueTypeTM-compatible fonts for Microsoft Windows 3.1
and Windows 95 are available on the floppy disk and CD-ROM supplied with your printer.
You can easily install them into your Windows system using our installer program. The
driver supports our unique compression mode to enhance printing speed in Windows
applications and allows you to set various printer settings including toner saving mode,
custom paper size, sleep mode, gray scale adjustment, resolution, and so forth. You can
easily setup these print options in the graphic dialog boxes through the Printer Setup
menu within the Windows Control Panel.
Printer Status Monitor with Bi-directional Parallel Interface
The printer driver can monitor your printers status using bi-directional parallel
communications.
The printer status monitor program can show the current status of your printer. When
printing, an animated dialog box appears on your computer screen to show the current
printing process. If an error occurs, a dialog box will appear to let you know what to
correct. For example: when your printer is out of paper, the dialog box will display No
Paper and instructions for the corrective action to take.
Versatile Paper Handling
The printer has a multi-purpose sheet feeder and a straight paper path mechanism.
Using this mechanism, you can load A4, letter, legal, B5, A5, A6, and executive sizes of
paper, and various types of media including envelopes, organizer paper, or your custom
paper size. The multi-purpose sheet feeder also allows manual paper loading, so you
can also use labels and transparencies.
Environment-Friendly
I-1
I-2
2.
2.1
SPECIFICATIONS
Printing
Print method
Laser:
Wave length:
Output:
Resolution
HL-820/1020:
HL-1040:
HL-1050:
2.2
780nm
5mW max
600 x 600dots/inch (for Windows)
600 x 600dots/inch (for Windows or DOS)
300 x 300dots/inch (under Apple Macintosh, DOS,
or other operating system)
1200(H) x 600(V)dots/inch (for Windows DIB
graphics)
600 x 600dots/inch (for Windows or DOS)
300 x 300dpi (under Apple Macintosh using
optional RS-100M)
Print speed
HL-820:
Up to 8 pages/minute
HL-1020/1040/1050: Up to 10 pages/minute
(when loading Letter-size paper from the multipurpose sheet feeder)
Warm-up
First print
15 seconds
(when loading Letter-size paper from the multipurpose sheet feeder)
Print media
Toner cartridge
Life Expectancy: 2,400 pages/cartridge
(when printing A4 or letter-size paper at 5% print coverage)
Developer
Functions
CPU
Emulation
HL-820/1020:
HL-1040:
HL-1050:
Printer driver
I-3
PR99017
2.3
Interface
Bi-directional parallel
Universal Serial Bus (USB) (HL-1050 only)
RS-422A/RS-232C serial (RS-100M) is optionally available. (HL1040/1050 only)
Memory
Control panel
Diagnostics
Self-diagnostic program
820W or less
280W or less
60W or less
13W or less
Noise
Printing:
Standing by:
49dB A or less
33dB A or less
Temperature
Operating:
Storage:
Humidity
Operating:
Storage:
Dimensions
(W x D x H)
Weight
Approx. 7.2kg (15.7lb.) including the drum unit and toner cartridge
Note:
x The peak figure of power consumption is worked out when the halogen heater lamp is
turned ON.
x The peak figure of power consumption is worked out excluding inrush current value.
x Be sure that the peak figure of power consumption is reference value and should be
used inside the Brother offices only.
I-4
2.4
Paper Loading
(1)
Feeding direction
(2)
Setting method:
Feedable paper weight: Same as in (1) for the multi-purpose sheet feeder.
Setting methods:
Cautions:
Before loading paper with holes such as organizer sheets, be sure to fan the stack
well.
When printing on the back of pre-printed paper, be sure to straighten the paper as
much as possible.
2.5
Print Delivery
(1)
(2)
Note:
Face down:
Environment :
I-5
PR98184
2.6
Paper
(1)
Paper type
Normal paper (60 to 157g/m2, specified types of high-quality paper)
(a)
A4 size
Letter size
Legal size
B5 (JIS ISO) size
A5 size
A6 size
Executive size
(C)
Basis Weight
Caliper
Moisture Content
Smoothness
4% to 6% by weight
100 to 250 (Sheffield)
Envelope
2
75 to 90 g/m (20 to 24 lb.)
single thickness
0.0033 to 0.0058 in.
(0.084 to 0.14 mm)
single thickness
4% to 6% by weight
100 to 250 (Sheffield)
Caution:
Although the printer can handle 9 inches (229mm) width paper such as the C4 size
envelope, you may get stains on the paper outside 8.5 inches width or on the back of
the paper.
It is recommended to use long-grained paper for the best print quality. If short-grained
paper is being used, it might be the cause of paper jams.
Use neutral paper. Do not use acid paper to avoid any damage to the printer drum
unit.
(2)
Name
2
60 to 80 g/m
Normal paper (cut sheet)
(100 sheets)
(30 sheets)
(50 sheets)
(10 sheets)
(10 sheets)
Envelopes
Organizers
I-6
Manual feed
(200 sheets)
Labels
Special paper (cut sheet)
Feeder
2.7
F
E
The effective printing area means the area within which the printing of all the data
received without any omissions can be guaranteed.
I-7
PR98184
The table below shows the effective printing areas.
Size
A4
Letter
Legal
B 5 (JIS)
B 5 (ISO)
Executive
A5
A6
Organizer
(J size)
Organizer
(K size)
Organizer
(L size)
COM-10
MONARCH
C4
C5
DL
210.0mm
8.27
(2,480 dots)
215.9mm
8.5
(2,550 dots)
215.9mm
8.5
(2,550 dots)
182.0mm
7.16
(2,149 dots)
176.0mm
6.93
(2,078 dots)
184.15mm
7.25
(2,175 dots)
148.5mm
5.85
(1,754 dots)
105.0mm
4.13
(1,240 dots)
69.85mm
2.75
(825 dots)
95.25mm
3.75
(1,125 dots)
139.7mm
5.5
(1,650 dots)
104.78mm
4.125
(1,237 dots)
98.43mm
3.875
(1,162 dots)
228.6mm
9.0
(2,700 dots)
162mm
6.38
(1,913 dots)
110mm
4.33
(1,299 dots)
297.0mm
11.69
(3,507 dots)
279.4mm
11.0
(3,300 dots)
355.6mm
14.0
(4,200 dots)
257.0mm
10.12
(3,035 dots)
250.0mm
9.84
(2,952 dots)
266.7mm
10.5
(3,150 dots)
210.0mm
8.27
(2,480 dots)
148.5mm
5.85
(1,754 dots)
127.0mm
5.0
(1,500 dots)
171.45mm
6.75
(2,025 dots)
215.9mm
8.5
(2,550 dots)
241.3mm
9.5
(2,850 dots)
190.5mm
7.5
(2,250 dots)
304.8mm
12.0
(3,600 dots)
229mm
9.01
(2,704 dots)
220mm
8.66
(2,598 dots)
203.2mm
8.0
(2,400 dots)
203.2mm
8.0
(2,400 dots)
203.2mm
8.0
(2,400 dots)
173.5mm
6.83
(2,007 dots)
164.0mm
6.46
(1,936 dots)
175.7mm
6.92
(2,025 dots)
136.5mm
5.37
(1,612 dots)
93.0mm
3.66
(1,098 dots)
56.2mm
2.21
(675 dots)
86.78mm
3.42
(975 dots)
131.23mm
5.17
(1,500 dots)
92.11mm
3.63
(1,087 dots)
85.7mm
3.37
(1,012 dots)
203.2mm
8.0
(2,400 dots)
150.0mm
5.9
(1,771 dots)
98.0mm
3.86
(1,157 dots)
288.5mm
11.36
(3,407 dots)
270.9mm
10.67
(3,200 dots)
347.1mm
13.67
(4,100 dots)
248.5mm
9.78
(2,935 dots)
241.5mm
9.5
(2,852 dots)
258.2mm
10.17
(3,050 dots)
201.5mm
7.93
(2,380 dots)
140.0mm
5.51
(1,654 dots)
118.5mm
4.66
(1,400 dots)
162.98mm
6.42
(1,925 dots)
207.43mm
8.17
(2,450 dots)
232.8mm
9.16
(2,750 dots)
182.0mm
7.16
(2,150 dots)
296.3mm
11.66
(3,500 dots)
220.5mm
8.68
(2,604 dots)
211.5mm
8.33
(2,498 dots)
E
3.4mm
0.13
(40 dots)
6.35mm
0.25
(75 dots)
F
4.23mm
0.17
(50 dots)
6.01mm
0.24
(71 dots)
6.35mm
0.25
(75 dots)
6.01mm
0.24
(71 dots)
6.35mm
0.25
(75 dots)
12.7mm
0.5
(150 dots)
6.01mm
0.24
(71 dots)
I-8
(Note that the paper sizes indicated here should conform to the nominal dimensions
specified by JIS.)
3.
3.1
SAFETY INFORMATION
Laser Safety (110 - 120V Model only)
This printer is certified as a Class 1 laser product under the US Department of Health and
Human Services (DHHS) Radiation Performance Standard according to the Radiation
Control for Health and Safety Act of 1968. This means that the printer does not produce
hazardous laser radiation.
Since radiation emitted inside the printer is completely confined within the protective
housings and external covers, the laser beam cannot escape from the machine during
any phase of user operation.
3.2
I-9
3.3
When the machine during servicing is operated with the cover open, the
regulations of VBG 93 and the performance instructions for VBG 93 are
valid.
CAUTION:
In case of any trouble with the laser unit, replace the laser unit itself. To
prevent direct exposure to the laser beam, do not try to open the enclosure
of the laser unit.
ACHTUNG:
(1)
Window
Fig. 1-1
(2)
Fig. 1-2
I-10
ELECTRONICS
1.1
External device
Low-voltage power
supply block
Control system
Interface block
Video control block
Operation block
(Operation panel)
High-voltage power
supply block
Erase lamp
Drive block
(Stepping motor)
Manual feed
Drum unit
Transfer block
Fixing unit
Developing
block
Cleaner
block
Drum
Charging
block
Fig. 2-1
II-1
HL-1040
External device
Control system
External device
Low-voltage power
supply block
Expansion I/O
Interface block
Video control block
Operation block
(Operation panel)
High-voltage power
supply block
Erase lamp
Drive block
(Stepping motor)
Manual feed
Drum unit
Transfer block
Fixing unit
Developing
block
Cleaner
block
Drum
Charging
block
Fig. 2-2
II-2
HL-1050
External device
Control system
Expansion I/O
External device
Low-voltage power
supply block
Interface block
Video control block
Operation block
(Operation panel)
High-voltage power
supply block
Erase lamp
Drive block
(Stepping motor)
Manual feed
Drum unit
Transfer block
Fixing unit
Developing
block
Cleaner
block
Drum
Charging
block
Fig. 2-3
II-3
1.2
(MC68EC000)
BUS
Oscillator (15.3MHz)
INT
Address Decoder
DRAM Control
Timer
RAM
(2.0 Mbytes)
FIFO
DATA EXTENSION
Soft Support
EEPROM (128
8 bits)
EEPROM I/O
Motor Driver
II-4
To PC
HL-1040
Fig. 2-5 shows the block diagram of the main PCB.
A S I C
CPU Core
Reset Circuit
(MC68EC000)
BUS
Oscillator (15.3MHz)
INT
Address Decoder
DRAM Control
Timer
RAM
(2.0 Mbytes)
FIFO
DATA EXTENSION
Soft Support
EEPROM (128
8 bits)
EEPROM I/O
Motor Driver
II-5
To PC
HL-1050
Fig. 2-6 shows the block diagram of the main PCB.
A S I C
CPU Core
Reset Circuit
(MB86831)
BUS
Oscillator (33.3MHz)
INT
Address Decoder
DRAM Control
Timer
RAM
(4.0 Mbytes)
FIFO
(max. 32Mbytes)
USB I/O
Option Serial I/O
(RS232C & RS422A)
Soft Support
EEPROM I/O
Motor Driver
Fig. 2-6
II-6
To PC
To PC
1.3
Main PCB
1.3.1
CPU Core
HL-820/1020/1040
Fig. 2-7 shows the CPU circuit block on the main PCB.
The CPU is a Motorola MC68EC000FN16 which is driven with a clock frequency of
15.3MHz. This clock frequency is made by dividing the source clock of 30.67 MHz into
two.
Fig. 2-7
II-7
HL-1050
Fig. 2-8 shows the CPU circuit block on the main PCB.
The CPU is a Motorola MB86831 which is driven with a clock frequency of 33MHz. The
CPU itself runs at 66MHz.
Fig. 2-8
II-8
1.3.2
ASIC
HL-820/1020/1040
The ASIC is composed of a Cell Based IC that contains the following functional blocks.
(1)
Oscillator circuit
Generates the main clock for the CPU by dividing the source clock frequency into
two.
(2)
Address decoder
Generates the CS for each device.
(3)
DRAM control
Generates the RAS, CAS, WE, OE and MA signals for the DRAM and controls
refresh processing (CAS before RAS self-refreshing method).
(4)
Interrupt control
Interrupt levels:
Priority
High
Low
(5)
NMI
FIFO
BD / Timer 1
SCANINT
Timer 2
Timers
The following timers are incorporated:
(6)
Timer 1
16-bit timer
Timer 2
10-bit timer
Timer 3
Watch-dog timer
FIFO
A 5,120-bit FIFO is incorporated. Data for one raster scan is transferred from the
RAM to the FIFO by DMA transmission and is output as serial video data. The
data cycle is 10.22 MHz.
(7)
II-9
BUSY
ACK
90 sec
0.5 sec
1.5 sec
0.5 sec
BUSY
ACK
BUSY goes HIGH at the falling edge of STROBE. The data (8 bits) from the PC is
latched in the data buffer at the rising edge of STROBE. The pulse width of ACK
differs according to the speed MODE as shown above. BUSY goes LOW at the
rising edge of ACK.
<IEEE1284 support>
This supports the IEEE1284 data transfer with the following modes.
Nibble mode
Byte
mode
(8)
Data expansion
This circuit expands the compressed image data received from the PC, and writes
the bit map data to the FIFO.
(9)
Software support
Supports 16 x 16 rotation, bit expansion, and bit search.
(10)
EEPROM I/O
One output port and one I/O port are assigned.
II-10
(11)
Fig. 2-9
II-11
HL-1050
The ASIC is composed of a Cell Based IC that contains the following functional blocks.
(1)
Oscillator circuit
Generates the main clock for the CPU.
(2)
Address decoder
Generates the CS for each device.
(3)
DRAM control
Generates the RAS, CAS, WE, OE and MA signals for the DRAM and controls
refresh processing (CAS before RAS self-refreshing method).
(4)
Interrupt control
Interrupt levels:
Priority
High
Low
10
9
8
7
6
5
4
3
2
1
Note:
All the interrupts can be masked.
The priority of levels 7, 6, and 5 are changeable from the program.
(5)
Timers
The following timers are incorporated:
(6)
Timer 1
32-bit timer
Timer 2
32-bit timer
Timer 3
Watch-dog timer
FIFO
A 10Kbit FIFO is included. Data for one raster scan is transferred from the RAM to
the FIFO by DMA transmission and is output as serial video data. The data cycle is
10.43MHz.
(7)
Parallel I/O
<Data receive Mode>
There are two modes in this unit. One is the CPU receive mode and the other is
the DMA receive mode. In the CPU receive mode the CPU receives the command
data from the PC, and after the CPU is switched to the DMA mode, it receives the
image data and writes it to the DRAM directly.
II-12
BUSY
ACK
90 sec
0.5 sec
1.5 sec
0.5 sec
BUSY
ACK
BUSY goes HIGH at the falling edge of the STROBE signal. The data (8 bits) from
the PC is latched into the data buffer at the rising edge of the STROBE signal. The
pulse width of ACK varies according to the speed MODE as shown above. BUSY
goes LOW on the rising edge of ACK.
<IEEE1284 support>
This supports the IEEE1284 data transfer with the following mode.
Nibble
Byte
ECP
(8)
mode
mode
mode
Data expansion
This circuit expands the compressed image data received from the PC, and writes
the bit map data to the FIFO.
(9)
Software support
Supports 16 x 16 rotation, bit expansion, bit search, and decimal point conversion.
(10)
EEPROM I/O
One output port and one I/O port are assigned.
II-13
(11)
Fig. 2-10
II-14
1.3.3
ROM
HL-820/1020/1040
A program file of 512 Kbytes and the font data are stored in the ROM. A 42-pin IC socket
is provided: a 16 Mbits ROM (42-pin) is mounted into this socket normally, but a 4 Mbits
ROM (40-pin) can be mounted by leaving the 1st and 42nd pins of the socket open
circuit.
Fig. 2-11
HL-1050
A program file of 4.0 Mbytes and the font data are stored in the ROM. Two 42-pin IC
sockets are provided: two 16 Mbits ROMs (42-pin) can be mounted into these sockets.
Fig. 2-12
II-15
1.3.4
DRAM
HL-820/1020/1040
A 16M-bit DRAM (x 16bits) is used as the RAM.
Fig. 2-13
HL-1050
Two 16M-bit DRAMs (x 16bits) are used as the RAM.
Fig. 2-14
II-16
1.3.5
Optional RAM
HL-1050
A 32bit (72 pin) SIMM can be fitted as optional RAM. The main PCB has one slot and the
capacity of SIMM can be from 1 Mbyte to 32 Mbytes.
Fig. 2-15
II-17
1.3.6
HL-1040/1050
The interrupt of the serial I/O is input to the EXINT terminal of the ASIC, and is
recognized by the CPU. A 32-byte register is provided for this I/O, which is read
and written to by the CPU.
Fig. 2-16
1.3.7
EEPROM
HL-820/1020/1040
The EEPROM is an XL24C01AF type of two-wire method with a 128 x 8 bits
configuration.
M62320FP is an IC which transfers the data received from the serial I/O to the parallel
I/O.
Fig. 2-17
HL-1050
The EEPROM is XL24C04AF type of two-wire method with a 512 x 8 bits configuration.
Fig. 2-18
II-18
1.3.8
Reset Circuit
HL-820/1020/1040
The reset IC is a PST598DNR. The reset voltage is 4.2V (typ.) and the LOW period of
reset is 200ms (typ).
Fig. 2-19
HL-1050
The reset IC is a PST596DNR. The reset voltage is 4.2V (typ.) and the LOW period of
reset is 50ms (typ).
Fig. 2-20
1.3.9
CDCC I/O
HL-820/1020/1040
Fig. 2-21 shows the CDCC interface circuit.
Fig. 2-21
II-19
HL-1050
Fig. 2-22 shows the CDCC interface circuit.
Fig. 2-22
II-20
Fig. 2-23
II-21
HL-1050
Fig. 2-24 shows the engine interface circuit.
Fig. 2-24
II-22
Fig. 2-25
HL-1050
The motor driver is a TR array. The excitation method is 2-2 phase excitation with a
bipolar drive.
Fig. 2-26
II-23
1.4
1.5
Power Supply
1.5.1
The power supply uses a switching regulation system to generate the regulated DC
power (+5V and +24V), which are converted from the AC line.
The regulated output and the production code of each power supply vary depending on
the printer model as listed below;
Model
HL-820/1020/1040
HL-1050
Regulated Output
+5V / 0.6 A
+24V / 2.0 A
+5V / 1.2A
+24V / 2.0A
Production Code
100V: MPW1547
200V: MPW1447
100V: MPW1550
200V: MPW1450
(Heater)
Thermal
Fuse
Lightning
Fuse
Surge
Heater
Absorber
Circuit
Lamp
Feedback
Line
Filter
Rectifier
Oscillator
24V
24V
Regulation
Circuit
5V
5V
Regulation
Circuit
Fig. 2-27
II-24
1.5.2
This generates and outputs the voltages and currents for the charging, development and
transfer functions.
R1
Current
Regulator
24VI
B1
Transfer Roller
Voltage
Regulator
Supply
Roller
Photosensitive
Drum
VR22
Cleaner
Roller
Developing
Roller
Current
Regulator
Corona
Unit
B81
Q81
Voltage
Regulator
B101 Q101
GND
Current
Regulator
B121 Q121
PAPER
SENSOR
PC141
Voltage
Regulator
Z51
VR51
Voltage
Regulator
VR71
Voltage
Regulator
VR61
Fig. 2-28
II-25
2.
MECHANICS
2.1
Drum Unit
Photosensitive Drum
Pinch Roller
Blade
Transfer
Roller
Erase Lamp
Fixing Unit
Hopper
Plate
Pressure Roller
Eject Roller
Eject Sensor
Actuator
Toner Cartridge
Polygon Mirror
Heat Roller
Thermistor
Development
Roller
Cleaning Roller
Toner Empty
Laser Scanner Sensor
Supply Roller
Corona Wire
Scanner Unit
Fig. 2-29
EL PCB
Scanner Unit
Main Motor
Sub Motor
Main Fan Motor
Sub Fan Motor
Panel
Sensor
PCB
HighVoltage
Power
Supply
Toner
Empty
Sensor
PCB
Fig. 2-30
II-26
Solenoid
Primary Charger (Corona Wire)
Primary Charger (Grid)
Developer Roller
Transfer Roller
Cleaner Roller
Supply Roller
Eject Sensor
Registration Sensor
Toner Empty Sensor
Thermistor (for Toner)
2.2
Paper Transfer
2.2.1
Paper Supply
The pick-up roller picks up one sheet of paper from the paper feeder every time it is
rotated and feeds it to the paper feed roller.
Pick-up roller
Papers
Hopper plate
Separation pad
Fig. 2-31
The paper is gripped between the pick-up roller and the separation pad and separated
into individual sheets.
The pick-up roller is directly connected to the sector gear, whose rotation is forcibly
stopped by the gear stopper. When the pick-up solenoid is activated, the clutch
mechanism is engaged by the solenoid action and the sector gear is driven; when it has
completed one full turn its rotation is stopped again by the gear stopper. The paper
drawn out by the pick-up roller pushes against the top of form sensor lever and the paper
top position/absence of paper is detected by sensing the motion of the lever.
2.2.2
Paper Registration
When paper picked up from the multi-purpose sheet feeder (MPF) pushes against the top
of form sensor actuator, the registration sensor lever is caused to turn, and the photo
sensor detects this motion. When this signal from the sensor is detected the paper feed
roller is stopped temporarily by the clutch. The paper is fed to the nip point between the
paper feed roller and the pinch roller in the multi-purpose sheet feeder, and the skew of
the paper is corrected by pushing the leading edge of the paper against the nip point.
When the paper feed roller starts to be rotated again when it is released by the clutch,
paper with the leading edge correctly aligned, is fed by the paper feed roller and is
transported to the transfer roller.
Paper
Pinch roller
Transfer roller
II-27
2.2.3
Paper Eject
When the leading edge of the paper pushes down the eject sensor actuator
located in the fixing unit, the photo sensor (photo interrupter) is opened and
detects the start of paper eject.
(b)
When the trailing edge of the paper has passed through the paper eject sensor
actuator, the photo sensor is closed and the completion of paper eject is
recognized.
Transfer roller
Pressure roller
Drum
Heat roller
Fig. 2-33
,
,
Paper
Sensor
High-voltage power
Eject sensor actuator
supply PCB
Sensor
Fig. 2-34
II-28
2.3
Sensors
2.3.1
Cover Sensor
Top Cover
Cover Switch
Fig. 2-35
2.3.2
Detects if there is toner in the toner cartridge. It also detects whether or not the drum unit
is installed. (The toner cartridge is installed in the drum unit).
Toner Empty
Sensor
Fig. 2-36
II-29
2.4
Drum Unit
2.4.1
Photosensitive Drum
Generates the latent electrostatic image and develops the image on the drum surface.
2.4.2
Primary Charger
Corona wire
Generates the ion charge on the drum.
(2)
Grid
Spreads the ion charge evenly over the drum surface.
2.4.3
Development Roller
Develops the latent electrostatic image on the drum surface by the addition of the toner.
2.4.4
Transfer Roller
Transfers the toner image to the paper from the drum surface.
2.4.5
Cleaner Roller
Erase Lamp
Print Process
2.5.1
Charging
The drum is charged to approx. +1150V by an ion charge which is generated by the
primary charger. The charge is generated by ionization of the corona wire, which has a
DC bias from the high-voltage power supply applied to it. The flow of the ion charge is
controlled by the grid to ensure it is distributed evenly on the drum surface. The drum
sleeve is regulated to approx. 280V by the voltage regulator.
280V
Passive Type
Voltage Regulator
Voltage
Regulator
+ + + -- +
++ - - - ++ + +
1150V
+ +
+ +
+ + +
+
+ ++
HVPS
Corona wire
Fig. 2-37
The primary charge uses a corona wire, but since the drum is positively charged, only
less than 1/10 of the usual quantity of ozone is generated compared with the negatively
charged drum. The level of ozone expelled from the printer is therefore not harmful to the
human body. Applicable safety standards have been complied with.
II-30
2.5.2
Exposure Stage
After the drum is positively charged, it is exposed to the light emitted from the laser unit.
Laser Beam
Drum
Paper
Laser beam
f lens
Laser detector
Polygon mirror
Laser diode
Motor
Lens
Fig. 2-38
The area exposed to the laser beam is the image to be printed. The surface potential of
the exposed area is reduced, forming the electrostatic image to be printed.
1 Cycle of drum
1
+1150
Primary charging
(a)
+700
(b)
+400
Drum +300
Sleeve
Time
Fig. 2-39
II-31
2.5.3
Developing
Developing causes the toner to be attracted to the electrostatic image on the drum so as
to transform it into a visible image.
The developer consists of a non-magnetic toner. The development roller is made of
conductive rubber and the supply roller (which is also made of conductive sponge) rotate
against each other. The toner is charged and carried from the supply roller to the
development roller. The toner adheres to the development roller and is conveyed to the
drum at an even thickness controlled by the blade. The toner is nipped between the
development roller and the drum and developed onto the latent image on the drum. The
electrostatic field between the drum and the development roller, which is DC-biased from
the high-voltage power supply, creates the electrostatic potential to attract toner particles
from the development roller to the latent image area on the drum surface.
(a) Transfer process [ON]
Transfer roller
Blade
Toner
Separator
Auger
Drum
Erase lamp
Develop housing
Supply roller
(b) Discharging process
DC-bias
SR-bias
Development
roller
Cleaning roller
Charger
Fig. 2-40
2.5.4 Transfer
(a)
Transfer process
After the drum has been charged and exposed, and has received a developed
image, the toner formed is transferred onto the paper by applying a negative
charge to the back of the paper. The negative charge applied to the paper causes
the positively charged toner to leave the drum, and adhere to the paper. As a
result, the image is visible on the paper.
(b)
II-32
Erasing Stage
Before the cleaning stage, the drum surface is exposed to the light emitted from the
erase lamp (LED lamp). This stage prepares the drum by decreasing its surface voltage
uniformly, ready to receive a uniform charge in the primary charging stage.
2.5.7
Fixing Stage
,
,,,,,,,,,
,
,
,
,
,,,,,,,,,
,,,,,,,,,
,
,
,
,,
The image transferred to the paper by static electricity is fixed by heat and pressure when
passing through the heat roller and the pressure roller in the fixing unit. The thermistor
ASSY keeps the surface temperature of the heat roller constant by detecting the surface
temperature of the heat roller and turning on or off the halogen heater lamp.
Pressure roller
,,,,
,,,,
Thermistor ASSY
Heat roller
Cleaner ASSY
Fig. 2-41
II-33
SAFETY PRECAUTIONS
To avoid creating secondary problems by mishandling, be careful to follow the following
precautions during maintenance work.
(1)
Always turn off the power switch and unplug the power cord from the power outlet
before accessing any parts inside the printer.
(2)
(3)
Be sure to apply grease to the gears and applicable positions specified in this
chapter.
(4)
When using soldering irons or other heat-generating tools, take care not to
accidentally damage parts such as wires, PCBs, and covers.
(5)
Before handling any PCBs, touch a metal portion of the equipment to discharge
any static electricity charge on your body, or the electronic parts or components
may be damaged.
(6)
When transporting PCBs, be sure to wrap them in the correct protective packaging.
(7)
(8)
When connecting or disconnecting cable connectors, hold the connector body, not
the cables. If the connector has a lock, release the connector lock first to release
it.
(9)
After a repair, check not only the repaired portion but also all connectors. Also
check that other related portions are functioning properly before operational
checks.
III-1
III-2
SCANNER UNIT
PAPER SUPPORT
19
18
FIXING UNIT
REAR COVER
TOP COVER
DRUM UNIT
13
10
BOTTOM
DRIVE UNIT
16
17
LOW-VOLTAGE
PS PCB ASSY
15
11
14
12
HIGH-VOLTAGE
PS PCB ASSY
2.
DISASSEMBLY FLOW
3.
DISASSEMBLY PROCEDURE
3.1
(2)
Press the hinges at the left and right sides of the output tray inwards to release the
output tray from the main cover.
Output Tray
Output Tray
Main Cover
3.2
Fig. 3.1
Drum Unit
(1)
(2)
Top Cover
Main Cover
Fig. 3.2
III-3
3.3
Top Cover
(1)
(2)
Press the hinges at the left and right sides of the top cover inwards to release the
top cover from the main cover.
Note:
It is recommended for easy removal to press the side of the top cover ( ) while pulling
the side of the main cover ( ).
Top Cover
Main Cover
Top Cover
Main Cover
Fig. 3-3
3.4
Rear Cover
(1)
(2)
Main Cover
Fig. 3-4
Note:
When re-assembling the rear cover, hook the two hooks at the right and left hand side
(rear), then secure the two screws.
III-4
3.5
Caution:
When disassembling the MP sheet feeder ASSY, if you get the grease on your fingers,
take care not to touch the separation pad or the paper pick-up roller, the grease spread to
the paper and the drum unit. It might cause black spots to appear on the printed page.
(1)
Push the left rib outwards and pull out the MP sheet feeder. It is not necessary to
release the right rib.
Multi-purpose
Sheet Feeder
Rib
Fig. 3-5
Note:
When re-assembling, apply a suitable amount of grease (2 rice-grain size) between the
heat sink of the motor and the ground leaf spring in case of grease shortage. (Refer to
the figure below.)
III-5
3.6
Fixing Unit
(1)
(2)
Lifting the fixing unit, disconnect the thermistor connector on the EL PCB first, then
the two heater harnesses.
Taptite, cup M4x16
Fixing Unit
EL PCB
Thermistor harness
Heater harness
(Blue)
Fig. 3-7
Note:
The eject sensor actuator may also be removed when removing the fixing unit. In this
case be sure to re-assemble the eject sensor actuator when re-assembling the fixing unit.
(3)
(4)
Open the fixing unit cover along the open side of the fixing unit cover.
Fixing unit cover
Fixing unit
cover
Pressure roller
Fig. 3-8
III-6
PR98292
(5)
(6)
Remove the four eject pinch rollers and the pinch springs from the fixing unit
frame. Then, remove the pinch spring from each pinch roller.
Pinch Spring
Fig. 3-8a
(7)
Remove the M3x10 self tapping screw securing the connector plate.
(8)
Remove the connector plate from the fixing unit frame and loosen the other M3x10
tapping screw securing the fixing unit cover.
(9)
Remove the idle gear 16 from the fixing unit frame to remove the heat roller. Then,
remove the halogen heater lamp from the heat roller.
Caution :
Never touch the surface of the halogen heater lamp and the heat roller.
Heat Roller Bearing
Heat roller
Taptite, pan
M3x10
Fig. 3-9
Note:
When re-assembling the bearing at the both ends of the heat roller, ensure that the
direction of the bearing is correct referring to the above figure.
The heat roller itself is very similar to the one for HL-1060/1070 printers. The heat
roller for the HL-820/1020/1040/1050 printers can be distinguished by the groove on
the edge of the roller. (Refer to the above figure.)
III-7
When replacing the heat roller cleaner with a new one, attach the cleaner referring to
the figure below;
-1mm ~ +1mm
4mm ~ 5mm
Fig. 3-10
Follow the instructions below when installing the thermistor in the fixing unit.
i) Place the cleaner felt of the cleaner ASSY for the thermistor under the heat roller.
ii) Place the end of the thermistor on the heat roller.
iii) Insert boss1 of the thermistor into the hole of the fixing unit frame.
iv) Do no place the thermistor on boss2 of the fixing unit frame.
,
,
,
,
,
,
,
,
,
,
,,,,,,,,,,,
, , ,,,,
,
Thermistor
Boss2
Heat Roller
,
,,
Boss1
Fig. 3-11
3.7
Scanner Unit
(1)
(2)
Main cover
III-8
Note:
When replacing the scanner unit, ensure to assemble the ferrite core using the cable
binder as follows;
Ferrite Core
Cable binder
Flat cable
LD harness
Fig. 3-13
(3)
(4)
Remove the M3x8 tapping screw, and lift the toner sensor PCB from the scanner
unit.
Caution:
Never touch the inside of the scanner unit or the mirror when disassembling or
reassembling. If there is any dirt or dust on the mirror, blow it off.
Taptite, cup M3x8
Scanner Unit
Fig. 3-14
III-9
3.8
(2)
Hold the hooks at the left and right of the mounting frame to pull out the main PCB
ASSY.
Hook
Main PCB ASSY
Screw, pan M4x6
Hook
Fig. 3-15
3.9
Caution:
Prior to turning the printer upside-down, ensure that the drum unit has been removed
from the printer.
(1)
(2)
Fig. 3-16
III-10
(3)
Lift the base plate ASSY and remove the grounding screw.
Ground wire
Screw pan(washer),
M3.5x6
Low-voltage Power
Supply PCB ASSY
Fig. 3-17
3.10
(2)
Remove the M4x12 screw securing the panel sensor PCB ASSY.
Main shield
Main shield
C
Panel Sensor PCB ASSY
Panel Sensor PCB ASSY
B
Fig. 3-18
Note:
When re-assembling the main shield, ensure that you fit PCB A to underneath the
main shield.
When re-assembling the panel sensor PCB, ensure that you fit the PCB into hook B
and hook C first. Then, fit the two bosses to the PCB and secure the screw.
III-11
(3)
Disconnect the eight connectors from the PCB. (Three connectors have already
been disconnected when removing the scanner unit.)
Panel Sensor
PCB ASSY
1
2
10
9
8
(Name of the Harnesses)
1. Low-voltage harness
2. Erase lamp harness
3. Toner harness
4. Scan motor flat cable
5. Laser harness
6. Solenoid harness
7. Main / sub motor connector
8. Fan motor 1 harness
9. Fan motor 2 harness
10. High-voltage flat cable
Main frame
Fig. 3-19
Note:
When re-assembling, the cable connectors must be inserted securely into the PCB
connectors and the PCB must not be stressed by the harnesses.
The connectors should be inserted by matching the housing color and the number of
pins.
3.11
Remove the one M4x12 tapping screw securing the low-voltage power supply PCB
ASSY.
(2)
Disconnect the two connectors for the heater harness and the LV harness from the
PCB.
Low-voltage Power Supply ASSY
Heater harness
LV harness
Fig. 3-20
III-12
(3)
Remove the one M4x12 screw to remove the inlet holder. Then, remove the inlet
and the PCB.
Note:
When re-assembling the inlet holder and AC inlet, be sure to insert the part A of the
holder into the hole of the ferrite core.
Inlet Holder
AC Inlet
Main Cover
Ferrite Core
Fig. 3-21
3.12
Remove the one M4x12 screw securing the high-voltage power supply PCB ASSY.
(2)
(2)
High-voltage Power
Supply PCB ASSY
Taptite, bind
M4x12
HV flat cable
Insulation Sheet
Main Cover
Fig. 3-22
III-13
3.13
Main Cover
Fig. 3-23
Note:
When re-assembling the sub fan motor, ensure that the side on which the manufacturers
sticker is attached is facing the main frame.
3.14
Remove the two M4x12 screws securing the fan motor holder.
(2)
(3)
Remove the main fan motor from the fan motor holder.
Fan motor holder
Taptite, bind M4x12
Taptite, bind
M4x12
Main frame
Fig. 3-24
III-14
PR980109
Fan motor holder
Note:
When re-assembling the fan motor
into the holder, refer to the figure on
the right.
Fan Motor
Fig. 3-25
3.15
Drive Unit
(1)
Hook
Fig. 3-26
(2)
Remove the three M4x20 and one M4x12 screws securing the drive unit.
Taptite, cup M4x20
Taptite, cup M4x12
Ferrite Core
(HL-1050 only)
Electrode DRB1
Ferrite Core
(HL-1050, 100V only)
Motor harness
Fig. 3-27
III-15
Note:
When re-assembling the drive unit, ensure that you fit the drive unit underneath the
electrode DRB1.
When disassembling the drive unit, be sure to remove the eight ferrite cores of two
types on the heater harness and the motor harness. (Refer to the figures in the
previous page, Fig. 3-26 and Fig. 3-27.) The place where the bigger core should be
assembled varies depending on the model.
3.16
(2)
Drive Unit
Fig. 3-28
3.17
(2)
Fig. 3-29
III-16
3.18
Paper Support
(1)
Pull the paper support down toward you and pull both legs outwards to release it.
MP Sheet Feeder
Paper Support
Fig. 3-30
3.19
Raise the extension support wire toward you and press both legs inward to release
it.
Output Tray
Fig. 3-31
III-17
4.
PACKING
Documents
Accessory carton
Pad
Printer
Bag
Pad
Carton
Fig. 3-32
III-18
INTRODUCTION
1.1
Initial Check
(1)
Operating environment
Check if :
The source voltage stays within 10% from the rated voltage shown on the rating
plate.
The printer is installed on a solid, level surface.
The room temperature is maintained between 10C and 32.5C. The relative
humidity is maintained between 20% and 80%.
The printer is not located in a dusty place.
The printer is not exposed to ammonia fumes or other harmful gases.
The printer is not located in a hot or humid area (such as near water or a
humidifier).
The printer is not exposed to direct sunlight.
The room is well-ventilated.
The printer is not placed where the ventilation hole of the printer is blocked.
(2)
Print paper
Check if :
A recommended type of print paper is being used. [If the paper is too thick or too
thin, or tends to curl, paper jams or paper feed problems may occur, or printed
images may be blurred.]
The print paper is damped. [If so, use fresh paper, and check whether the print
quality improves or not.]
The print paper is short-grained paper or acid paper. [If so, print quality problems
may occur. For further information, refer to paper specifications in Chapter II.]
(3)
Consumables
Check if :
The Toner lamp is not lit on the control panel when a toner cartridge is installed in
the printer. [If the lamp is lit, replace the cartridge with a new one. If blank spots
occur on printouts, take out the drum unit and slowly rock it to redistribute the
toner evenly.]
(4)
Others
Condensation:
When the printer is moved from a cold room into a warm room in cold weather,
condensation may occur inside the printer, causing various problems as listed
below:
Condensation on the optical surfaces such as the scanning mirror, lenses, the
reflection mirror and the protection glass may cause the print image to be light.
If the photosensitive drum is cold, the electrical resistance of the photosensitive
layer is increased, making it impossible to obtain the correct contrast when
printing.
IV-1
Basic Procedure
If a malfunction or incorrect print appears, make an initial check following the basic
procedure below:
(1)
Check the error lamps following the inspection proc edure described later in
this section. If no error lamps are lit, see Section 4 for troubleshooting information.
(2)
If any defective image output is found, follow the image defect fault descriptions in
this section.
IV-2
2.
CONSUMABLE PARTS
2.1
Drum Unit
The Drum lamp is on when the drum unit is nearly at the end of its life.
Life expectancy:
Note:
There are many factors that determine the actual drum life, such as temperature,
humidity, type of paper and toner that you use, the number of pages per print job, etc..
2.2
Toner Cartridge
Toner low:
The Data and Alarm lamps blink once every five seconds.
Toner empty:
Life expectancy:
Note:
Toner life expectancy will vary depending on the type of average print job printed.
2.3
No.
1
Part No.
Qty
Remarks
Fixing Unit
UL8750001
(50,000)
120V
Fixing Unit
UL8751001
(50,000)
230V
Scanner Unit
UL8748001
(50,000 or more)
UL8749001
(50,000 or more)
Note:
The above table shows only estimated values. They are subject to change without prior
notice.
IV-3
3.
IMAGE DEFECTS
3.1
I-1 Light
I-2 Dark
I-10 Faulty
registration
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Fig. 4.1
IV-4
I-22 Ghost
3.2
Caution:
Print quality can not be guaranteed in the following cases;
When using the printer for a special job, such as printing of name cards.
When printing much narrower paper than printable paper width.
When printing on one area of the paper continuously even though Letter or A4-size
paper is used.
I-1
Possible cause
Toner sensing
failure
Light
Step
Check
Result
Remedy
Yes
Yes
No
(printer side)
Toner sensing
failure
(toner cartridge
side)
Drum
connection
failure
High-voltage
power supply
PCB failure
No
If the connection is
normal, replace the
high-voltage power
supply PCB.
Panel sensor
PCB or main
PCB failure
No
Scanner unit
failure
Yes
IV-5
HV.GND
contacts
(Fig.4-5)
Clean contact
electrodes both in the
printer body and on
the drum unit.
I-2
Dark
Possible cause
Step
Corona failure
(soiled wire)
Corona failure
(contact failure)
Check
Is the corona wire dirty?
Result
Remedy
Yes
No
Yes
High-voltage
power supply
PCB
No
Main PCB
No
Panel sensor
PCB
No
IV-6
HV.GND
contacts
(Fig.4-5)
I-3
Completely blank
Possible cause
Step
Developing bias
contact failure
Drum unit
Check
Remedy
Yes
Yes
connected correctly?
No
Yes
Scanner harness
connection failure
No
Reconnect the
connector properly.
Yes
Yes
No
Scanner unit
failure
HV.GND
contacts
(Fig.4-5)
Result
IV-7
I-4
All black
Possible cause
Corona failure
Step
Check
Result
Remedy
Yes
Yes
Harness
connection
No
High-voltage
power supply
PCB
Yes
Ditto
Yes
Main PCB
Yes
Panel sensor
PCB
Yes
IV-8
HV.GND
contacts
(Fig.4-5)
I-5
Possible cause
Fixing unit
Step
1
Check
Result
Yes
Remedy
Clean the pressure roller.
(See the following note.)
Yes
No
IV-9
I-6
Possible cause
Corona failure
Step
1
Corona failure
Scratch on the
drum
Cleaning failure
Scratch on the
heat roller
Check
Is the corona wire dirty?
Result
Yes
Yes
Remedy
Clean the corona
wire with the wire
cleaner.
Return the wire
cleaner to its home
position.
Yes
Yes
Yes
Yes
HV.GND
contacts
(Fig.4-5)
Note:
If you print the same pattern continuously, the drum will be worn and black vertical
streaks will appear on the paper.
I-7
Possible cause
Scratch on the
drum
Toner stuck on
the developer
roller
Step
1
2
Check
Are the horizontal stripes at
94mm (OPC drum) intervals?
Are the horizontal stripes at
25mm (developer roller)
intervals?
Result
Yes
Remedy
Replace the drum unit.
Yes
Scratch on the
fixing roller
Yes
High-voltage
power supply
PCB
Yes
IV-10
I-8
Possible cause
Translucent
stain on the
scanner window
I-9
Step
1
Check
Are there any stains on the
scanner window?
Result
Yes
Remedy
Clean the scanner window.
If it is not effective, replace the
scanner unit.
Result
Yes
Remedy
Clean the scanner window with
a dry tissue.
Replace the drum unit.
Possible cause
Scanner window
dirty
Transfer failure
I-10
Step
1
2
Check
Is the scanner window dirty?
Is the transfer roller scratched?
Yes
Faulty registration
Possible cause
Excessive paper
load
Step
1
Print paper
Ditto
Paper resist
sensor position
incorrect
Check
Is the paper loaded in the
paper feeder more than 22mm
deep?
Is the specified weight of the
recommended paper being
used?
Is the first printing position
within 1mm of the tolerance
specification?
Is the position of the paper
resist sensor normal?
IV-11
Result
Yes
Remedy
Instruct the user to keep paper
loads below 22mm in depth.
No
Yes
No
I-11
Poor fixing
Possible cause
Step
Check
Result
Remedy
Printing paper
Yes
Toner sensing
failure
Yes
Toner is empty.
The toner sensing is defective,
clean the toner sensor.
Thermistor
failure
No
Low-voltage
power supply
PCB failure
Yes
Result
Remedy
I-12
Image distortion
Possible cause
Scanner
Step
1
Check
Is the scanner unit secured to
the frame incorrectly?
Yes
Yes
Yes
Scanner motor
rotation failure
Scanner
connection
failure
Is it coming loose?
IV-12
I-13
Faint print
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
o tnirp tset tuo tnirP o tnirp tset tuo tnirP tset tuo tnirp tset tuo tnirp tset tuo tnirP
Print out test print out test print out test Print out test print o Print out test print o
Possible cause
Step
No
Drum unit
Yes
Scanner window
dirty
Yes
Scanner unit
failure
Yes
I-14
Toner cartridge
Environment
Result
Remedy
White spots
Possible cause
Print paper
Check
Step
1
Check
Result
Remedy
Yes
No
Yes
Yes
IV-13
I-15
Black spots
Possible cause
Drum unit
Step
1
Check
Are the spots at 94mm
intervals?
The problem is not solved after
printing a few pages.
Result
Yes
Fixing unit
Yes
High-voltage
power supply
PCB
Yes
Remedy
If toner remains stuck, wipe it
off gently with a cotton swab.
Replace the drum unit if the
OPC drum is scratched or
deteriorated (exposed).
(Refer to the following note.)
Check and clean the heat roller
with a cloth dampened with
alcohol.
Replace the fixing unit.
Replace the high-voltage
power supply PCB.
Position of smudge on
the drum
94mm interval
Fig. 4-2
(2) Turn the drum gear by hand while looking at the surface of the OPC drum.
Fig. 4-3
IV-14
(3) Wipe the surface of the photosensitive drum with a cotton swab until the dust
or paper powder on the surface comes off.
Separator
Paper path
Cleaning roller
Toner cartridge
Caution:
Do not wipe the surface of the photosensitive drum with something sharp. (ball-point
pen etc.)
Use the cleaning liquid which is a 50-50 mixture of ethyl alcohol and pure water.
I-16
Black band
Possible cause
Step
Check
Result
Remedy
Drum unit
No
Ditto
Yes
IV-15
I-17
Gray background
Note:
This problem may appear on the first 10 to 20 pages immediately
after replacing the toner cartridge.
Possible cause
Print paper
Step
1
Drum unit
Check
Does the paper being used
meet the paper specification
(weight, etc.).
Result
Remedy
No
Yes
Yes
No
I-18
Hollow print
Possible cause
Print paper
Step
1
Check
Is thick paper of more than
42lb being used or extremely
rough surface paper?
IV-16
Result
Remedy
Yes
No
I-19
Possible cause
Step
Check
Result
Remedy
Drum unit
Yes
High-voltage
power supply
PCB
Yes
I-20
Horizontal lines
Step
Check
Result
Remedy
HV.GND
contacts
(Fig.45,4-7)
SR electrode
Yes
SR connection
failure
No
Check the SR
connection.
Feed roller
No
Possible cause
IV-17
I-21
Light rain
Check
Result
Remedy
Possible cause
Step
Yes
High-voltage
power supply
PCB failure
Yes
**Note:
Make sure to use a used drum unit which has already ejected the starter sheet. It is not
possible to find the drum unit failure if you use a new drum unit with a starter sheet in it.
I-22
Possible cause
Driver setting
Ghost
Step
1
Check
Result
2
Yes
Remedy
Change the current mode to
the normal mode from the
driver setting.
Print 5 or 6 blank pages if this
problem occurs.
IV-18
3.3
Drum shaft
High-voltage contacts
Grounding wire
For transfer
roller
Drum unit
For cleaning
roller
For development
roller
Wire cleaner
For grid
For corona wire
Fig. 4-5
For development
roller
For grid
For cleaning
roller
For grid
Fig. 4-6
IV-19
For development
roller
3.4
IV-20
4.
PAPER JAM
Problem
Type of jam
Cause
Temp measure
Jam at power on
Paper stuck
No paper
Same as above.
1. Cover open
(single printing)
Same as above.
Same as above.
(continuous printing)
2. Bug
2. Bug
IV-21
5.
TROUBLESHOOTING MALFUNCTIONS
When carrying out countermeasures for malfunctions as described in this section, check
connectors for contact failure before measuring the voltage at the specified connector
pins.
M-1
No AC power supplied
Possible cause
Supply voltage
Step
1
Power plug
Wiring
M-2
Check
Is the correct voltage present
at the outlet?
Is the power cord securely
plugged into the outlet?
Is the fuse blown?
Result
No
No
Yes
Yes
Remedy
Inform the user that the correct
voltage is not supplied at the
outlet.
Plug the power cord securely
into the outlet.
If the fuse blows again
immediately after replacing the
low-voltage power supply PCB,
check that there is not a short
circuit somewhere in the AC
power supply line.
Replace the AC power cord.
No DC power supplied
Possible cause
AC power
supply
Step
1
Wiring, DC load
Low-voltage
power supply
PCB
Check
Is AC power supplied between
connectors CN1-L and CN1-N
when the power plug is
plugged into the outlet?
Turn the power switch OFF
and disconnect the P13
connector (panel sensor PCB).
Turn the power switch ON
again. Measure the voltages
between the terminals.
Do the measured voltage
satisfy the prescribed value in
the table below?
PCB
Panel
Sensor
Voltage
P8-1
P8-4
Approx. 24V
P8-2
P8-3
Approx. 5V
Result
No
Remedy
Follow the same check
procedure of M-1 No AC
power supplied.
Yes
No
Caution:
If you analyze malfunctions with the power plug inserted into the power outlet, special
caution should be exercised even if the power switch is OFF because it is a single pole
switch.
IV-22
M-3
Possible cause
Failure of
connector
Step
1
Main PCB
Sub motor
unrotated
M-4
Approx.4.5
Approx.4.5
Approx.9.1
Approx.9.1
Result
No
Remedy
Reconnect the connector.
No
Yes
No
No paper supplied
Possible cause
Connection
failure
Panel sensor
PCB circuit
Check
Is the connection of connector
P9 on the panel sensor PCB
correct?
Disconnect connector P9 from
the panel sensor PCB.
Measure the resistance
between the connector pins of
the main motor by using a
circuit tester.
Do the measured resistances
satisfy the prescribed values in
the table below?
Step
1
Paper pick-up
clutch solenoid
MP tray unit
failure
Main PCB
Check
Is the contact of connector P3
on the panel sensor PCB
good?
Set paper in the manual paper
slot and make a test print by
pressing the switch on the
control panel.
Does the voltage between pins
2 (SOLENOID) and 1 (24V) of
the P3 connector on the panel
sensor PCB change from
approx. 24V DC to 0V within
the specified time?
Is the surface of the separation
pad or the pick up roller
stained or worn out?
Is the problem solved by
replacing the main PCB?
IV-23
Result
No
Remedy
Reconnect the connector.
No
Yes
Yes
Yes
M-5
Possible cause
Step
Check
Result
Remedy
High-voltage
contact
Yes
High-voltage
power supply
PCB
Yes
No
M-6
Possible cause
Step
Check
Result
Remedy
Poor thermistor
harness contact
No
Blown thermal
fuse
Yes
Yes
No
Yes
Is it open circuit?
Thermistor
failure
Halogen heater
lamp failure
M-7
BD failure
Possible cause
Harness
connection
failure
Step
Check
Result
No
IV-24
Remedy
Connect it securely.
M-8
Scanner failure
Possible cause
Step
Check
Result
Remedy
Harness
connection
failure
No
Power supply
input
No
Yes
IV-25
F-1
Double feeding
Possible cause
Step
Check
Result
Remedy
Paper
Is paper of a recommended
type being used?
No
Separation pad
Yes
Check
Result
Remedy
F-2
Possible cause
Paper
Wrinkles
Step
1
Is paper of a recommended
type being used?
No
Yes
Fixing unit
entrance guide
Yes
Fixing unit
Yes
No
IV-26
6.
INSPECTION MODE
6.1
(2)
With the top cover open, turn on the power switch while holding down the switch
on the control panel.
When you enter this inspection mode, the Drum lamp is ON. Holding down the
panel switch will cause the lamps to turn ON in the order Drum
Alarm
Ready
Data
Drum. When you release the switch, a mode is selected.
The mode selected is indicated by the lamp which is ON when you release the
switch.
The inspection modes are assigned to the respective lamps as shown below.
Lamp
Type of inspection
Drum
Alarm
Ready
Data
Drum + Alarm *
Alarm + Ready *
RAM check
Ready + Data *
IV-27
Drum
Alarm
Registration sensor
Ready
(Paper)
Cover sensor
Data
(Toner)
Toner sensor
Switch
Fig. 4.8
Paper eject
ON (Paper is detected.)
Drum lamp ON
sensor
Registration
ON (Paper is detected.)
Alarm lamp ON
sensor
Cover
sensor
Ready lamp ON
Toner
sensor
Data lamp ON
Turn the printer power switch OFF, open the top cover, and remove the drum unit.
(2)
Turn the printer power switch ON while holding down the control panel switch. The
Drum lamp comes ON.
(3)
(4)
Check that the Drum (paper eject sensor) and Alarm (registration sensor)
lamps go OFF after all the lamps have been ON.
If the paper eject sensor is ON at this point, the Drum lamp stays ON (error).
If the registration sensor is ON at this point, the Alarm lamp stays ON (error).
(5)
(6)
(7)
(8)
(9)
If all the sensors are correct, the printer goes back to the Ready status. If
any error is detected, the corresponding lamp stays ON.
IV-28
6.2
Error Codes
In the event of a printer failure, error codes will be indicated as shown below. All the
lamps and the specific lamps are turned ON alternately. The specific combination of
lamps that are ON indicates the type of the error.
Type of error
Fuser Malfunction
Laser BD Malfunction
Scanner Malfunction
ROM Error
D-RAM Error
Service A *
Service B *
Service C
Service D
Service E0
Service E1
Service P
NV-RAM Error
CPU Runtime Error *
Data
Ready
Alarm
Drum
Service A:
Address Error
Service B:
Bus Error
Alarm
Ready
(Paper)
Data
(Toner)
Time delay
: OFF
: ON
Fig. 4-9
IV-29
PR99136
E:
F:
G:
H:
May
June
July
August
J:
K:
L:
M:
September
October
November
December
XXXXXXL7S111101
SERIAL NO.
FACTORY NO.
YEAR
MONTH
MODEL NO.
(2)
6D30 0 0 0 ANB
YEAR
MONTH
TONER TYPE
DATE
LINE NO.
SERIAL NO.
(3)
6EB000001
YEAR
SERIAL NO.
MONTH
ASSEMBLY
(4)
SERIAL NO.
DATE
MONTH
(X: OCT., Y: NOV., Z: DEC.)
YEAR
MONTH (X: OCT., Y: NOV., Z: DEC.)
DATE (0: 1-9, 1: 10-19, 2: 20 or later
YEAR
FACTORY ID NO.
(5)
2 8 0 0 1
SERIAL NO.
ID NO.
1:HL-700 SERIES, 8: HL-820/1020/1040/1050, 9:HL-1060
FACTORY ID NO.
A-1
AC INPUT
INLET
P1 CDCC I/F
POWER
SW
CN101
LVPS
CN1
MAIN PCB
MAIN
MOTOR
P2 ENGINE I/F
SOLENOID
P1 ENGINE
P9
P3
P2
CN1
P4
P6
REGISTRATION
SENSOR
FAN1
(60x60mm)
FAN2
(80x80mm)
P8
P11
P7
P10
SCANNER
MOTOR
P1
LD PC8
PH1
TONER
SENSOR
PH2
P5
P1
SUB
MOTOR
SCANNER UNIT
SW2
P1
COVER SW
ERASE LAMP
LEDs
SR.B
T/R
DRM.B
VCLM
GRID DEV
HVPS
PC141
CN1
PAPER SENSOR
THERMISTOR
HEATER
A-2
SW1
PANEL SENSOR
PCB
AC INPUT
SERIAL I/F
INLET
RS-100M
P3 OP I/O
P1 CDCC I/F
POWER
SW
CN101
LVPS
CN1
MAIN PCB
MAIN
MOTOR
P2 ENGINE I/F
SOLENOID
P9
P3
P2
CN1
P4
P6
REGISTRATION
SENSOR
FAN1
(60x60mm)
FAN2
(80x80mm)
P8
P11
P7
P10
SCANNER
MOTOR
P1
LD PC8
PH1
TONER
SENSOR
PH2
P5
P1
SUB
MOTOR
P1 ENGINE
SCANNER UNIT
SW2
P1
COVER SW
ERASE LAMP
LEDs
SR.B
T/R
DRM.B
VCLM
GRID DEV
HVPS
PC141
CN1
PAPER SENSOR
THERMISTOR
HEATER
A-3
SW1
PANEL SENSOR
PCB
AC INPUT
SERIAL I/F
INLET
RS-100M
CN101
LVPS
POWER
SW
SLIOT SIMM
CN1
P1 CDCC I/F
P3 OP I/O
P2
USB I/F
MAIN PCB
MAIN
MOTOR
P2 ENGINE I/F
SOLENOID
P9
P3
P2
CN1
P4
P6
REGISTRATION
SENSOR
FAN1
(60x60mm)
FAN2
(80x80mm)
P8
P11
P7
P10
SCANNER
MOTOR
P1
LD PC8
PH1
TONER
SENSOR
PH2
P5
P1
SUB
MOTOR
P1 ENGINE
SCANNER UNIT
SW2
P1
COVER SW
ERASE LAMP
LEDs
SR.B
T/R
DRM.B
VCLM
GRID
DEV
HVPS
PC141
CN1
PAPER SENSOR
THERMISTOR
HEATER
A-4
SW1
PANEL SENSOR
PCB
CODE
UK4007000
NAME
B48K312CIR
V-5
CODE
UK4007000
NAME
B48K312CIR
A-6
CODE
UK4041000
NAME
B512001CIR
A-7
CODE
UK4041000
NAME
B512001CIR
A-8
CODE
UK4041000
NAME
B512001CIR
A-9
CODE
UK4041000
NAME
B512001CIR
A - 10
CODE
UK4041000
NAME
B512001CIR
A - 11
CODE
UK4010000
NAME
B48K303CIR
A - 12
Appendix 13. Low-voltage Power Supply PCB Circuit Diagram, HL-820/1020/1040 (110 - 120V)
L
N
SW1
F1
C1
FG
NTC1
Z1
L1
C7
C15
D11 D14
+
C5
D13 D12
BEA1
C8
Q1
C22
PC2
R18
R5
R23
R2
TRA1
Z2
C16
D7
R11
R22
C9
Q2
C13
R8
R20
R6
R13
R21
R7
C10
D4
D6
C11
CN1
R10
PC1
R9
R17
B
R101
PC1
D101
D104
D110
FG
C101
R103
C110
D102
R105
C102
+
R102
R106
Q101
VR101
R104
IC101
C103
+
R115
R113
R114
R110
PC2
CN101
2,3
24V
5V
REM
GND
NAME
A - 13
Low-voltage
PS Circuit (110 - 120V)
Appendix 14. Low-voltage Power Supply PCB Circuit Diagram, HL-820/1020/1040 (220 - 240V)
SW1
F1
C1
Z1
FG
NTC1
L1
C7
R1
D11 D14
C5
BEA1
D13 D12
C8
Q1
R18
C22
R23
R5
R3
PC2
R2
R22
TRA1
Z2
C9
Q2
D7
R8
R6
C13
R11
CN1
PC1
R10
R17
D6
C11
R21
D4
R9
C10
R20
R7
R13
T1
A
D101
D104
EG
R101
C101
PC1
D102
C110
IC101
R105
C103
+
R115
R102
R106
Q101
C102
+
D110
R103
VR101
R104
R113
R114
R110
PC2
CN101
2,3
24V
5V
REM
GND
A - 14
NAME
Low-voltage
PS Circuit (220 - 240V)
Appendix 15. Low-voltage Power Supply PCB Circuit Diagram, HL-1050 (110 - 120V)
N
SW1
F1
C1
FG
Z1
NTC1
C15
C7
D11
D14
D13
D12
L1
+
C5
BEA1
C17
C8
Q1
C22
R18
PC2
R4
D2
R5
R23
R2
TRA1
Z2
C16
D7
R11
R6
R13
R22
C9
Q2
C13
R8
R20
R21
R7
C10
D4
D6
C11
CN1
PC1
R10
R9
R17
B
R101
R102
R106
FG
PC1
D104
Q101
D101 BEA101
D110
R103
C110
D102
C101
R105
VR101
R104
C102
+
IC101
C103
+
R115
R113
R114
R110
PC2
R116
R117
CN101
2,3
24V
5V
REM
GND
NAME
A - 15
Low-voltage
PS Circuit (110 - 120V)
Appendix 16. Low-voltage Power Supply PCB Circuit Diagram, HL-1050 (220 - 240V)
SW1
F1
C1
Z1
FG
NTC1
L1
C7
R1
D11 D14
C5
BEA1
D13 D12
C8
Q1
R18
C22
R23
R5
R3
C9
Q2
R22
TRA1
Z2
PC2
R2
D7
R20
R6
R8
C13
R21
R7
R13
R11
D4
C10
PC1
R10
C11
CN1
R9
R17
D6
T1
D101
A
BEA101
EG
+
R101
PC1
D110
C101
A
D102
R102
R106
Q101
C102
+
D104
C110
IC101
R105
R103
VR101
R104
C103
+
R115
R113
R114
R110
R116
PC2
R117
CN101
2,3
24V
5V
REM
GND
NAME
A - 16
Low-voltage
PS Circuit (220 - 240V)
P1
+24V
CHG
0V
11
10
DEVCH2 2
DEVCH1 1
DEV
VCLN
TRANSFF 8
SR
TRANSFB 7
PSENS
CN1
CN1
CN1
CN1
CN1
CN1
CN1
CN1
CN1
CN1
CN1
R1
R2
R103
R121
R102
R104
Q3
R12
R13
Q5
Q4
C3
D2
R25
Q1
C25
C24
B1
C82
R81
C22
C81
R82
DEV
CHG
CN2
D22
D81
C27
GRID
CN6
D128
DRM . B
C28
Q25
Q26
CN5
D87
R134
CN3
D23
D21
Q23
Q24
Q27
D71
D82
VR21 R33
D25 D24
C26
D5
PC22
R34
Q22
R72 R71
C23
R17
D4
PC21
R14
R16 D3
+
C1
C4
R27
C21
R15
R28
R26
CN4
VCLN
R90
C73
R67
Q71
D72
R68
R74 R73
D85
D86
D125
R91
Q61
Q63
B81
D104
C85
R109
Q65
Q62
Q64
Q81
R89
B101
D105
B121
D126
R111 R110
C86
R7
R92
D88
Q101
R108
D103
Q121
R133
C127
C125
R135
R113
C106
C72
R75
C104
R112
C128
R10
C2
Q2
VR71
C84
C105
R11
C5
R65
D62
C103
C107
R23
R64
VR61
C82
D83
R6
R9
C61
C83
D82
R5
C52
C62
C81
D84
C124
C126
Z51
D61
R87
R88
R114
R107
D102
R132
D127
D101
D123
R128
R131
C102
C123
D124
IC81
C121 R129
IC121
PC141
D122
R86
D52
R126
VR121
R106
R24
R4
D1
Q21
Q51
R85
C101
Q52
R83
R84
D81
Q6
R22
R8
R61
R3
R21
R105 VR101
C122
R51
Q82
R123
D121
R125
R124
C51
VR51
R82
R101
D51
Q102
Q122
R127
R81
R122
T/R
CN7
SR . B
NAME
A - 17
High-voltage PS Circuit
APPENDIX 18.
If you want to know the drum unit life or the number of printed pages, you should
print out the test print page (for HL-820/1020) or the print configuration page(s) (HL1040/1050).
Print Test Print or Print Configuration
1) Turn on the power switch of the printer while pressing the control panel
switch.
2) Release the panel switch when the Drum lamp comes on.
3) Press the panel switch and release it when the Alarm lamp comes on.
4) Print the page(s) of Test Print or Print Configuration.
Note:
The design of Test Print and Print Configuration vary depending on the printer
model. Refer to the figures below;
The ** marks in the figures show the page counter. They are not printed in
some countries.
<HL-820/1020>
<HL-1040>
(**)
(**)
<HL-1050>
(**)
A-18
PR98092
How to Read the Drum Life
The bar shown below is printed at the bottom of Test Print / Print
Configuration.
0%
100%
00000030303030202
Value in a unit of 1
000000E0D0D0D0D0D
0 00 00 0E 0D 0D 0D 0D 0D
60,000 x 0 + 600 x 0 + 14 + 13 + 13 + 13 + 13 + 13 = 79
A-19
APPENDIX 19.
Parts Name
Diameter (Circumference)
Transfer Roller
OPC Drum
Heat Roller
Pressure Roller
A-20